Reliability analysis and hypothesis testing of critical success factors of total productive maintenance

Abstract

PurposeThis paper deals with concept of total productive maintenance (TPM) and its implementation approach. It also presents the identification of critical factors for effective implementation of TPM. The reliability analysis identified potential areas where more concentration is required. The application of hypothesis testing in productivity maintenance should be promoted by parametric test and significantly instrumental in explanation of phenomena. It is also indispensable to better understand quality data and provide guidance to production control.Design/methodology/approachThe various critical success factors of TPM implementation has organised into set of eight performance measure and thirty three sub-factors for getting the in-depth details of each indicator. The paper identifies the reliability of these factors and understands the problem with greater clarity and its ramification. Researcher collected responses from forty one manufacturing organisations through structured designed questionnaire. The reliability analysis was carriedout by calculating the value of Cronbach's alpha method. To draw the meaningful conclusions supported by relevant empirical data, provisional formulation is required, and it was carried by hypothesis testing. In this test, samples are taken from a population with known distribution (normal distribution), and a test of population parameters is executed. It determines the relevancy of facts directs the researcher's efforts into productive channels. The statements were hypothetically tested by calculating the arithmetic value of Chi-Square (χ2) and MINITAB-19 software was used for identification of p-value.FindingsThis study identified that main factors and sub-factors of TPM which are critical for implementation of TPM. The study also avoids the complexities involved in implementing TPM by reliability analysis. It is found that all identified CSFs are reliable as Cronbach's alpha is above 0.6. The hypothesis testing shows that all alternative hypothesis statements are acceptable as Chi-Square (χ2) value has satisfied the conditions and null hypothesis are true as calculated p-value is less than the 0.05 for eight identified TPM critical factor.Originality/valueIn this paper researcher provides a comprehensive typology of TPM-CSFs, and its ranking and importance in manufacturing sector. The preparedness of such study related to TPM implementation is becoming a major sourcing base for the world and there is a paucity of such studies. Such studies are equally important in a global context.

Relationship between TPM practices and operational performance in soft drinks manufacturing industry

“…The long-term elements are more focused on new equipment designs that involve the innovation practice (McKone et al. , 1999; Ahuja and Khamba, 2008; Kalpande and Toke, 2022).…”

“…Skill levels are improved by training and practiced in the right way where constant repetition leads to error-free and consistent performance. EDT focused on importance of maintenance and its effective way to improve productivity and should be conducted for operators, maintenance personnel and managers (Kalpande and Toke, 2022).…”

“…As per Wickramasinghe and Perera (2016) it include subareas such as to ensure safe work environment, provide appropriate work environment and eliminate incidents of injuries and accidents. Kalpande and Toke (2022) stated that this pillar emphasizes creating and maintaining a safe and healthy workplace and is important to foster a safe environment when implementing TPM. Under this pillar, maintenance activities should be reviewed to determine its effect on safety and health in the workplace and all companies should have zero accidents and health damage targets.…”

The Impact of Single Minute Exchange of Die and Total Productive Maintenance on Overall Equipment Effectiveness

“…Brah & Chong (2004) found out that the business performance of companies with implemented TPM is significantly superior to non-TPM companies. Improved maintenance process using TPM enhances manufacturing performance and customer satisfaction (Kalpande & Toke, 2022). Implementing TPM leads to an increase in Overall Equipment Effectiveness (Gherghea et al, 2021).…”

Analysis of maintenance outsourcing challenges for belt conveyors in the Industry 4.0 era

“…Total productive maintenance (TPM) is another concept that engages all members, from operators to managers, to maximize the machine reliability and overall management of plant assets (Modgil and Sharma, 2016). The TPM approach is a cornerstone of quality management in today’s competitive environment (Kalpande and Toke, 2023). Since the beginning of the industrial revolution, maintenance philosophies have progressed from reactive maintenance to preventive maintenance (Kaparthi and Bumblauskas, 2020) and finally to the notion of condition-based maintenance (Jasiulewicz-Kaczmarek et al , 2020).…”